Hand Placing Flash Die To Make USB Drives

April 27, 2013 by Mike Szczys 34 Comments

It’s a stretch to call this one a hack, but USB thumb drives are around us constantly and we always assumed that the boards inside were machine populated (like with a pick and place machine). [Bunnie] tells us otherwise. He recently had the chance to tour a factory where USB flash drives are made.

The image above shows a worker populating a set of boards with the flash memory dies. The waffle-grid to the right holds the dies. Each is a tiny glint of a component. The worker is not in a clean room, and is using a bamboo tool to pick up the pieces. [Bunnie] explains that he’s seen the tools before but doesn’t fully comprehend how they work. He figures that the hand-cut manipulator has just the right amount of grab to pick up the die, but will also release it when it touches down on the dot of glue applied to the landing zone on the board.

If you’re into this sort of thing you should check out the PCB factory tour we saw a couple of years back. The article link is dead but the embedded tour video still works.

[Thanks pl]

OTM-02 Is A 3D Printed Wristwatch

April 23, 2013 by Mike Szczys 27 Comments

We love looking at roll-your-own wristwatch projects. Getting a project small enough to carry around on your wrist is a real challenge. But we think the OTM-02 wristwatch really hit the form factor right on the mark.

OTM stands for Open source Time Machine. It’s the work of [Hairy Kiwi] and he managed to bring the guts of the watch in at a thickness between 6.5 and 7mm. That includes the LCD, PCB, piezo diaphragm, and the battery. The PCB itself is a four-layer board built on 1mm thick substrate. It’s running an EFM32 (ARM) microcontroller which comes with hardware USB support. The little door sitting open on the side of the 3D printed enclosure provides access to the micro USB connector which can be used to charge the 150 mAh battery inside. That may not sound like much juice, but if you set the display to show minutes only [Hairy] calculates a battery life approaching 175 days. If you just have to have the seconds displayed you can expect about two weeks between charges.

Like the name says, this project is Open Source.

[Thanks Liam]

Drop-in Pcb Makes Nintendo Four Score A USB Joystick

April 21, 2013 by Mike Szczys 12 Comments

The Nintendo Four Score was a controller attachment for the original Nintendo Entertainment System which allowed you to use four controllers at one time. [Simon Inns] wanted to use some original NES controllers on his computer so he developed a drop-in replacement board that converts the device to USB.

As we’ve seen with other NES controller hacks, the hardware uses a simple parallel to serial shift register to deliver key-presses to the console. This means that reading four controllers at a time is no different than shifting in data to a microcontroller from the four different sources. The remaining portion of the problem is providing a USB connection that enumerates the device as a joystick. We’ve seen a bunch of USB projects from [Simon] so it’s no surprise that he was able to pull it off.

He went with the ATmega16U2 which has built-in support for USB. [Simon] wrote the code so that although there is only one USB cable, each of the four controller ports will appear as a separate USB joystick on the computer. To button up the project he carefully measured the original board and laid out his own version so that it fits the footprint of all the original components as well as the mounting brackets on the case. Top notch [Simon]!

Horribly Complicated Electric Guitar Keyboard

April 12, 2013 by Mike Szczys 32 Comments

the-email-gutar

Gutarist, hacker, and mustache enthusiast [David Neevel] brought together way too many pieces of hardware in order to use his electric guitar as a computer keyboard.

So let’s dig into the house of cards he built for the project. It starts off with the guitar which has been fitted with an additional pickup to interface with a Roland GR-33 synthesizer pedal. That outputs a MIDI signal, which many hackers would have connected to the computer and parsed with a simple script. But not [David], he connected it to an Arduino via an optisolator. Well that’s not too ridiculous, right? Don’t you think he’ll just parse the MIDI signals and push them to the computer via the Arduino’s USB port? Wrong! He translates the MIDI signals into combinations for a big relay board which is emulating the key matrix of an old USB keyboard. But as you can see in the demo video after the jump it works quite well.

If you’re more of the drumming sort there’s an electric drum set version of this hack too.

Continue reading “Horribly Complicated Electric Guitar Keyboard” →

Wall Wart Computer Mouse

April 9, 2013 by Mike Szczys 92 Comments

SAMSUNG

This rather bulky looking wall wart is actually a computer mouse. Sure, it may cause your hand to cramp horribly if used for any length of time. But some would say it’s worth that for the hipster value of the thing.

The rather odd shape is somewhat explained by the fact that this was sourced from Ikea. After gutting the transformer found inside the plastic case he had plenty of room to work with. He drilled a hole so that the sensor from a Logitech USB optical mouse can pick up the movement of the mouse. He also got pretty creative when it came to the buttons. The two prongs of the wall plug pivot horizontally to affect the momentary press switches inside.

After the break you can see a quick demo of the project. [Alec] doesn’t consider it to be complete. He wants to make a couple of improvements which include adding weight to make it feel more like the original wall wart, and finding a way to hide the hole he drilled for the sensor.

Continue reading “Wall Wart Computer Mouse” →

Wooden Teeth For Your USB Keyboard

March 29, 2013 by Mike Szczys 15 Comments

wooden-keyboard

We just got an ergonomic keyboard for the first time and absolutely love it. But the look of this keyboard hack has us second guessing ourselves. [Will Pretend] pulled off an absolutely stunning wooden retrofit for his USB keyboard. Be warned, his project log includes 175 photos, and most of them have captions.

He started off by taking apart the original USB keyboard to see what he was working with. Before digging in to the valuable wood stock he cut test pieces using some thin MDF. But once he had a clear plan to get to the end of the project it was full stem ahead.

The keys are not simple Chicklet style overlays, they have depth like you would expect to find on low-grade plastic peripherals. This was accomplished by milling each key, then sending them through the laser cutter to each the letter on top.

Take some time to make your way through the entire project (here’s a thumbnail layout if you get frustrated). Unfortunately [Will] says he doesn’t actually use the keyboard because of grains catching and the keys move around a bit too much. But it does work.

Hacking The Right Side Of A Keyboard Completely Off

March 23, 2013 by Mike Szczys 12 Comments

hacking-the-right-side-of-your-keyboard

The form factor of this keyboard just doesn’t look right. What’s missing? Oh, the numpad has been completely removed! We use our numpad almost exclusively (especially when coding) so it’s a little hard to figure out why [Ludw] did this. His only mention of motive is that he wanted the mouse closer to the main part of the keyboard and that he didn’t use the numpad. No matter what the reason, we still think he did an amazing job of giving new life to the older keyboard.

It started out as a plain old beige Cherry G80-3000 keyboard. After cracking open the case [Ludw] carefully traced out the connections between the key matrix and the PCB which provides the USB connection. This is because the controller is mounted over on the part of the PCB he his about to remove. Before making the cuts he desoldered all seventeen switches (these can be reused to fabricate a new keyboard, or add switches to various projects). He then lopped off the depopulated substrate and used point-to-point soldering to reconnect the controller. A bit of case alteration removed the extra space while also reusing the nicely molded edges. A clean and tidy paint job finishes the hack.

[via Reddit]